Functionally gradient aluminum alloy products and methods of making

ABSTRACT

The present disclosure generally provides aluminum alloy products having a functional gradient across at least one dimension of the aluminum alloy product. The disclosure also provides articles of manufacture made from such products, and methods of making such products, such as through casting and rolling. The disclosure also provides various end uses of such products, such as in automotive, aerospace, marine, defense, transportation, electronics, and industrial applications.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application No. 63/198,018, filed Sep. 24, 2020, which is hereby incorporated by reference in its entirety.

FIELD

The present disclosure generally provides aluminum alloy products having a functional gradient in at least one dimension of the product. The disclosure also provides methods of making aluminum alloy products having a functional gradient in at least one dimension, such as through direct chill casting and rolling. The disclosure also provides various end uses of such products, such as in automotive, aerospace, marine, transportation, electronics, defense, and industrial applications.

BACKGROUND

Aluminum alloy products are desirable for use in a number of different applications, especially those where light weight, strength, and durability are desirable. For example, aluminum alloys are increasingly replacing steel as a structural component of automobiles and other transportation equipment. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials reduces the weight of the equipment and allows for substantial improvements in energy efficiency. Even so, the use of aluminum alloy products can pose certain challenges.

One particular challenge relates to flat rolled aluminum alloy products and attempts to manufacture such products to exhibit multiple properties. Such properties may include mechanical properties, such as Young's modulus, Poisson's Ratio, shear modulus, density, conductivity, and the coefficient of thermal expansion. Such properties may also include corrosion, bond durability, and anodizing. Attempts to control these properties may rely on the combination of multiple materials, such as with fusion casting or roll bonding. Products made from multiple materials, however, lack recyclability and still may not achieve the desired properties.

SUMMARY

The covered embodiments of this disclosure are defined by the claims, not this summary. This summary provides a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings, and each claim.

In an aspect, described are methods of preparing a functionally gradient aluminum alloy product. A method of this aspect may include casting an ingot in a mold or casting a molten liquid to a casting cavity to form a cast product. The cast product may include an aluminum alloy. The cast product may include at least one peritectic forming element and at least one eutectic forming element. The casting may include: a) forming primary grains enriched in the at least one peritectic forming element and depleted in the at least one eutectic element and b) controlling movement and accumulation of the primary grains. The method may include homogenizing the cast product, wherein during homogenization, the primary grains are precipitated. The method may include rolling the homogenized cast product to form the functionally gradient aluminum alloy product.

In embodiments, the method may include the aluminum alloy comprising a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

In embodiments, the method may include the at least one peritectic forming element being present in an amount of 0.2% by weight or less.

In embodiments, the method may include the at least one eutectic forming element being present in an amount of greater than 0.2% by weight.

In embodiments, the method may include casting an ingot in a mold using a direct chill casting process.

In embodiments, the method may include casting a molten liquid to a casting cavity using a continuous casting process.

In embodiments, the method may include a continuous casting process that includes casting with at least one of a twin-belt caster, a twin-roll caster, a block caster, or any other continuous caster.

In embodiments, the rolling may include hot rolling.

In embodiments, the method may include the precipitated primary grains inhibiting recrystallization during the rolling.

In embodiments, the method may include the aluminum alloy product being functionally gradient across a thickness of the product.

In embodiments, the method may include the aluminum alloy product being functionally gradient across a width of the product.

In embodiments, the method may include wherein the primary grains have a largest dimension from 25 to 250 microns.

In embodiments, the method may include the aluminum alloy including the at least one peritectic forming element and the at least one eutectic forming element.

In embodiments, the method may include the at least one peritectic forming element, the at least one eutectic forming element, or combinations thereof being added to the ingot or to the liquid metal during casting.

In embodiments, the method may include forming primary grains further includes forming at least one of solute elements, intermetallic particles, solute rich grains, reinforcement particles, or combinations thereof.

In another aspect, described are aluminum products having a functional gradient across at least one dimension, wherein the functional gradient comprises an unrecrystallized center and a recrystallized surface, and/or a reinforcement particle proportion variation from center to surface.

In embodiments, the product may include at least one peritectic forming element in the unrecrystallized center.

In embodiments, the product may include the at least one peritectic forming element includes at least one of Ti, Zr, V, Hf, Nb, Ta, Cr, or combinations thereof.

In embodiments, the product may include the at least one peritectic element being present in an amount of 0.2% by weight or less.

In embodiments, the product may include at least one eutectic forming element in the recrystallized surface.

In embodiments, the product may include the eutectic forming element includes at least one of Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce, and Y and combinations thereof.

In embodiments, the product may include the eutectic forming element being present in an amount of greater than 0.2% by weight.

In embodiments, the product may include at least one reinforcement particle.

In embodiments, the reinforcement particle may include at least one of TiB₂, TiC, NbB₂, Al₂O₃, SiC, ZrB₂, AlB₂, Al₃Ti, Al₇Cr, Al₃Zr, Al₃Nb, Al₃Ta, Al₃V, AlN, Al₃Ni, Al₃Hf, Al₃HfO, and combinations thereof.

In embodiments, the reinforcement particle is either added to molten metal or formed in-situ during casting.

In embodiments, the reinforcement particle is present in an amount greater than 0.1% by weight.

In another aspect, described are aluminum alloy articles inducing the aluminum alloy product of any of the above.

The disclosure also provides an aluminum alloy product made by the processes disclosed herein.

Also disclosed are articles of manufacture comprising the disclosed aluminum alloy product. In some embodiments, the article of manufacture comprises a rolled aluminum alloy product. Examples of such articles of manufacture include, but are not limited to, a component of an automobile, truck, trailer, train, railroad car, airplane, such as a body panel or other part for any of the foregoing, a bridge, a pipeline, a pipe, a tubing, a boat, a ship, a storage container, a storage tank, an article of furniture, a window, a door, a railing, a functional or decorative architectural piece, a pipe railing, an electrical component, a conduit, a beverage container, a food container, or a foil. In some embodiments, the articles of manufacture are automotive or transportation body parts, including motor vehicle body parts (e.g., bumpers, side beams, roof beams, cross beams, pillar reinforcements, inner panels, outer panels, side panels, hood inners, hood outers, and trunk lid panels). The articles of manufacture can also include aerospace products and electronic device housings.

Additional aspects and embodiments are set forth in the detailed description, claims, non-limiting examples, and drawings, which are included herein.

DETAILED DESCRIPTION

The present disclosure provides flat rolled aluminum alloy products that have a functional gradient across at least one dimension of the product. These products may exhibit a functional gradient, formed during at least one manufacturing step, while retaining recyclability and other desirable mechanical properties. The disclosed functionally gradient aluminum alloy products have final properties, including hardness, tensile strength, and elongation, which vary along a dimension of the functional gradient. Typically, composite materials, i.e., products made by joining different materials, have distinct interfaces, resulting in changes in properties. These interfaces may fail by delamination of the materials. By purposefully forming a functional gradient, the distinct interfaces are replaced with a gradient interface. The gradient interface allows for a smooth transition in properties from one material, or region of material, to another. Accordingly, delamination does not occur.

Forming a functional gradient in an aluminum alloy product is especially helpful for flat rolled products formed by fusion casting or roll bonding in order to improve formability or corrosion resistance. Such products, however, suffer from a lack of recyclability because the material can no longer be recycled back into its individual pieces.

The functionally gradient materials described herein take advantage of segregation behavior that occurs during direct chill casting, rather than trying to avoid or correct it. Typically, for a given region, certain peritectic forming particles may be enriched at the ingot center and eutectic forming particles may be depleted at the ingot center. Such segregation has been believed to be problematic and is typically deemed a defect. Thus, traditional methods aim at characterizing and eliminating the segregation, rather than purposefully encouraging and controlling it. The functionally gradient materials described herein may also take advantage of segregation behavior that occurs during continuous casting, such as during twin-roll casting or twin-belt casting. In continuous casting, a centerline segregation forms along the strip thickness. Unlike with direct chill casting, the twin-belt or twin-roll caster produces positive segregation at the center, and this centerline segregation may be used to produce a functional gradient in alloy products.

The functional gradient of the aluminum alloy products described herein may be understood by beginning with primary grains formed during the casting process. These grains, which have a largest dimension from 25 microns to 250 microns, comprise both peritectic forming elements and eutectic elements. “Peritectic forming elements” refer to elements, such as titanium (Ti), zirconium (Zr), vanadium (V), niobium (Nb), hafnium (Hf), tantalum (Ta), and chromium (Cr), which form a single solid phase by the reaction of a different solid phase with a liquid. “Eutectic forming elements” refer to elements, such as silicon (Si), copper (Cu), magnesium (Mg), scandium (Sr), iron (Fe), cerium (Ce), and Zinc (Zn), which form two different solid phases by decomposition of a single phase liquid.

An increase in eutectic forming element(s) above the maximum solid solubility (as per the simple binary eutectic phase diagram) increases the proportion of eutectic around the primary aluminum grain. Once the local chemistry reach above the eutectic chemistry, a eutectic phase (“D phase”) will form. The eutectic phase at center can be manipulated by steering the casting parameters or by changing the alloy chemistry.

Below the maximum solid solubility in primary aluminum (as per the simple binary peritectic phase diagram), the peritectic fraction and peritectic phase (“A” phase) increases with increases in the peritectic forming element. Casting an alloy chemistry that includes peritectic forming elements higher than the maximum solid solution, the liquid that delivered to cast will already have fine peritectic phase, and hence during continuous casting, for example, these peritectic element rich primary aluminum grains or as “primary grains” will be moved to the center of the strip during casting resulting in a gradient structure strip. Whether using direct casing or continuous casting, segregation of phases other than the primary grains may also be possible including segregation of solute elements, intermetallic particles, solute rich grains, and reinforcement particles. An example of a peritectic phase predominantly found in the strip center compared to the surface of an 6xxx alloy includes intermetallic Al₃Ti particles. Another example is reinforcement particles such as at least one of TiB₂, TiC, NbB₂, Al₂O₃, SiC, ZrB₂, A1B2, Al₃Ti, Al₇Cr, Al₃Zr, Al₃Nb, Al₃Ta, Al₃V, AlN, Al₃Ni, Al₃Hf, Al₃HfO, and combinations thereof.

The peritectic forming elements are generally used to control recrystallization behavior in aluminum alloy products, but their segregation behavior is typically ignored because they are present in small amounts, e.g., 0.2% by weight or less. By preferentially segregating peritectic forming elements, e.g., elements forming a dispersoid, the recrystallization behavior of the rolled aluminum alloy product can be controlled through the thickness of the product.

As described herein, the segregation may be controlled at various points in the manufacturing process, and by various methods. In some aspects, the segregation is controlled during the casting process. Examples include controlling the sedimentation and accumulation of the primary grains by various methods. For example, during casting, e.g., direct chill casting, the flow pattern within the ingot may be controlled to spatially distribute the primary grains. In some aspects, the at least one of primary grains, solute elements, intermetallic particles, solute rich grains, reinforcement particles, or combinations thereof can be formed in-situ. In some aspects, the casting speed may be adjusted. In some aspects, convective currents may be applied while casting, such as by magnetic means or physical stirring. Further, the segregation may be controlled during a homogenization treatment. During this treatment, the primary grains may be precipitated, allowing for inhabitation of recrystallization where the grains have precipitated. Such a method allows for a gradient microstructure through the thickness of the resulting flat rolled product. In some aspects, the grain growth may even be manipulated after recrystallization, such as by selectively heating the rolling ingot through its thickness. This may allow for controlling an additional gradient in the grain morphology. For example, the temperature profile may be varied while rolling, such as by using magnetic, microwave, or inductive heating methods.

Definitions and Descriptions

As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “7xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

As used herein, a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm. For example, a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

Reference may be made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A Ti condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin-belt caster, a twin-roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.

As used herein, the meaning of “room temperature” can include a temperature of from about 15° C. to about 30° C., for example about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, the meaning of “ambient conditions” can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar. For example, relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere in between. For example, barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.

All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Unless stated otherwise, the expression “up to” when referring to the compositional amount of an element means that element is optional and includes a zero percent composition of that particular element. Unless stated otherwise, all compositional percentages are in weight percent (wt. %).

As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

In the following examples, the aluminum alloy products and their components are described in terms of their elemental composition in weight percent (wt. %). In each alloy, the remainder is aluminum, with a maximum wt. % of 0.15% for the sum of all impurities.

Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.

Unavoidable impurities, including materials or elements, may be present in the alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some impurities typically found in aluminum include iron and silicon. The alloy, as described, may contain no more than about 0.25 wt. % of any element besides the alloying elements, incidental elements, and unavoidable impurities.

Aluminum Alloy Product

In at least one aspect, the present disclosure provides an aluminum alloy product comprising an aluminum alloy material having a functional gradient in at least one dimension. In some non-limiting aspects, the functional gradient may be across the thickness of the aluminum alloy product. In other aspects, the functional gradient may be across the width of the aluminum alloy product.

The aluminum alloy product can comprise any suitable aluminum alloy material ranging from 1xxx series aluminum alloys to 8xxx series aluminum alloys. In some embodiments, the aluminum alloy material is a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some embodiments, the aluminum alloy material is a 5xxx series aluminum alloy that comprises, among other elements, less than or equal to 0.2% by weight of a peritectic forming element (e.g., Ti, Zr, or Cr) and greater than 0.2% by weight of a eutectic forming element (e.g., Si, Cu, or Mg). In some aspects, the total content of the peritectic forming element is less than or equal to 0.2% by weight. In other aspects, each peritectic forming element is present in an amount of less than or equal to 0.2% by weight. In some aspects, the total content of the eutectic forming element is greater than 0.2% by weight. In other aspects, each eutectic forming element is present in an amount of greater than 0.2% by weight. In some embodiments, the aluminum alloy comprises the peritectic forming element and/or the eutectic forming element in the prescribed amounts. In other aspects, some or all of the eutectic forming element and/or some or all of the peritectic forming element desired in the aluminum alloy product may be added to the ingot during casting.

By way of non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, 7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

As described herein, a peritectic forming element may be present in an amount of 0.2% by weight or less. In some aspects, each peritectic forming element is present in an amount of 0.2% by weight or less. In other aspects, the total for all peritectic forming elements is 0.2% by weight or less. Peritectic forming elements include Ti, Zr, V, Nb, Hf, Ta and Cr.

In certain aspects, the aluminum alloy includes titanium (Ti) in an amount up to approximately 0.2% (e.g., from 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy can include approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.011%, approximately 0.012%, approximately 0.013%, approximately 0.014%, approximately 0.015%, approximately 0.016%, approximately 0.017%, approximately 0.018%, approximately 0.019%, approximately 0.02%, approximately 0.021%, approximately 0.022%, approximately 0.023%, approximately 0.024%, approximately 0.025%, approximately 0.026%, approximately 0.027%, approximately 0.028%, approximately 0.029%, approximately 0.03%, approximately 0.031%, approximately 0.032%, approximately 0.033%, approximately 0.034%, approximately 0.035%, approximately 0.036%, approximately 0.037%, approximately 0.038%, approximately 0.039%, approximately 0.04%, approximately 0.05%, approximately 0.051%, approximately 0.052%, approximately 0.053%, approximately 0.054%, approximately 0.055%, approximately 0.056%, approximately 0.057%, approximately 0.058%, approximately 0.059%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.2% Ti. All expressed in wt. %.

In some aspects, the aluminum alloy includes zirconium (Zr) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%, based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% Zr. In certain aspects, Zr is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes vanadium (V) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%, based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% V. In certain aspects, V is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes niobium (Nb) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%, based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% Nb. In certain aspects, Nb is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes hafnium (Hf) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%, based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% Hf. In certain aspects, Hf is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes tantalum (Ta) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%, based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% Ta. In certain aspects, Ta is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes chromium (Cr) in an amount from 0% to approximately 0.2% (e.g., from 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.001%, approximately 0.002%, approximately 0.003%, approximately 0.004%, approximately 0.005%, approximately 0.006%, approximately 0.007%, approximately 0.008%, approximately 0.009%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.11%, approximately 0.12%, approximately 0.13%, approximately 0.14%, approximately 0.15%, approximately 0.16%, approximately 0.17%, approximately 0.18%, approximately 0.19%, or approximately 0.20% Cr. In certain aspects, Cr is not present in the alloy (i.e., 0%). All expressed in wt. %.

As described herein, a eutectic forming element may be present in an amount of greater than 0.2% by weight. In some aspects, each eutectic forming element is present in an amount greater than 0.2% by weight. In other aspects, the total for all eutectic forming elements is greater than 0.2% by weight. Eutectic forming elements include Si, Cu, Mg, Sc, Fe, Ce, Zn, as well as Ni, Sr, Ca, and Y.

In some aspects, the aluminum alloy includes silicon (Si) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Si. In certain aspects, Si is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes copper (Cu) in an amount from 0% to approximately 7% (e.g., from 0.2% to 6.8%, from 0.25% to 6.75%, from 0.3% to 6.5%, or from 0.4% to 5%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, approximately 2%, approximately 2.05%, approximately 2.1, approximately 2.15%, approximately 2.2%, approximately 2.25%, approximately 2.3%, approximately 2.35%, approximately 2.4%, approximately 2.45%, approximately 2.5%; approximately 2.6%, approximately 2.65%, approximately 2.7%, approximately 2.75%, approximately 2.8%, approximately 2.85%, approximately 2.9%, approximately 2.95% approximately 3%, approximately 3.05%, approximately 3.1%, approximately 3.15%, approximately 3.2%, approximately 3.25%, approximately 3.3%, approximately 3.35%, approximately 3.4%, approximately 3.45%, approximately 3.5%, approximately 3.55%, approximately 3.6%, approximately 3.65%, approximately 3.7%, approximately 3.75%, approximately 3.8%, approximately 3.85%, approximately 3.9%, approximately 3.95%; approximately 4%, approximately 4.05%, approximately 4.1%, approximately 4.15%, approximately 4.2%, approximately 4.25%, approximately 4.3%, approximately 4.35%, approximately 4.4%, approximately 4.45%, approximately 4.5%, approximately 4.55%, approximately 4.6%, approximately 4.65%, approximately 4.7%, approximately 4.75%, approximately 4.8%, approximately 4.85%, approximately 4.9%, approximately 4.95%; approximately 5%, approximately 5.05%, approximately 5.1%, approximately 5.15%, approximately 5.2%, approximately 5.25%, approximately 5.3%, approximately 5.35%, approximately 5.4%, approximately 5.45%, approximately 5.5%, approximately 5.55%, approximately 5.6%, approximately 5.65%, approximately 5.7%, approximately 5.75%, approximately 5.8%, approximately 5.85%, approximately 5.9%, approximately 5.95%; approximately 6%, approximately 6.05%, approximately 6.1%, approximately 6.15%, approximately 6.2%, approximately 6.25%, approximately 6.3%, approximately 6.35%, approximately 6.4%, approximately 6.45%, approximately 6.5%, approximately 6.55%, approximately 6.6%, approximately 6.65%, approximately 6.7%, approximately 6.75%, approximately 6.8%, approximately 6.85%, approximately 6.9%, approximately 6.95%, or approximately 7% Cu. In certain aspects, Cu is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes magnesium (Mg) in an amount from 0% to approximately 7% (e.g., from 0.2% to 7%, from 0.25% to 7%, from 0.3% to 6.5%, or from 0.4% to 5%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, approximately 2%, approximately 2.05%, approximately 2.1, approximately 2.15%, approximately 2.2%, approximately 2.25%, approximately 2.3%, approximately 2.35%, approximately 2.4%, approximately 2.45%, approximately 2.5%; approximately 2.6%, approximately 2.65%, approximately 2.7%, approximately 2.75%, approximately 2.8%, approximately 2.85%, approximately 2.9%, approximately 2.95% approximately 3%, approximately 3.05%, approximately 3.1%, approximately 3.15%, approximately 3.2%, approximately 3.25%, approximately 3.3%, approximately 3.35%, approximately 3.4%, approximately 3.45%, approximately 3.5%, approximately 3.55%, approximately 3.6%, approximately 3.65%, approximately 3.7%, approximately 3.75%, approximately 3.8%, approximately 3.85%, approximately 3.9%, approximately 3.95%; approximately 4%, approximately 4.05%, approximately 4.1%, approximately 4.15%, approximately 4.2%, approximately 4.25%, approximately 4.3%, approximately 4.35%, approximately 4.4%, approximately 4.45%, approximately 4.5%, approximately 4.55%, approximately 4.6%, approximately 4.65%, approximately 4.7%, approximately 4.75%, approximately 4.8%, approximately 4.85%, approximately 4.9%, approximately 4.95%; approximately 5%, approximately 5.05%, approximately 5.1%, approximately 5.15%, approximately 5.2%, approximately 5.25%, approximately 5.3%, approximately 5.35%, approximately 5.4%, approximately 5.45%, approximately 5.5%, approximately 5.55%, approximately 5.6%, approximately 5.65%, approximately 5.7%, approximately 5.75%, approximately 5.8%, approximately 5.85%, approximately 5.9%, approximately 5.95%; approximately 6%, approximately 6.05%, approximately 6.1%, approximately 6.15%, approximately 6.2%, approximately 6.25%, approximately 6.3%, approximately 6.35%, approximately 6.4%, approximately 6.45%, approximately 6.5%, approximately 6.55%, approximately 6.6%, approximately 6.65%, approximately 6.7%, approximately 6.75%, approximately 6.8%, approximately 6.85%, approximately 6.9%, approximately 6.95%, or approximately 7% Mg. In certain aspects, Mg is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes scandium (Sc) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Sc. In certain aspects, Sc is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes iron (Fe) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Fe. In certain aspects, Fe is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes cerium (Ce) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Ce. In certain aspects, Ce is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes zinc (Zn) in an amount from 0% to approximately 10% (e.g., from 0.01% to 10%, from 0.05% to 9%, from 0.1% to 9%, or from 0.15% to 9%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.1%, approximately 1.2%, approximately 1.3%, approximately 1.4%, approximately 1.5%, approximately 1.6%, approximately 1.7%, approximately 1.8%, approximately 1.9%, approximately 2%, approximately 2.1%, approximately 2.2%, approximately 2.3%, approximately 2.4%, approximately 2.5%, approximately 2.6%, approximately 2.7%, approximately 2.8%, approximately 2.9%, approximately 3%, approximately 3.1%, approximately 3.2%, approximately 3.3%, approximately 3.4%, approximately 3.5%, approximately 3.6%, approximately 3.7%, approximately 3.8%, approximately 3.9%, approximately 4%, approximately 4.1%, approximately 4.2%, approximately 4.3%, approximately 4.4%, approximately 4.5%, approximately 4.6%, approximately 4.7%, approximately 4.8%, approximately 4.9%, approximately 5%, approximately 5.1%, approximately 5.2%, approximately 5.3%, approximately 5.4%, approximately 5.5%, approximately 5.6%, approximately 5.7%, approximately 5.8%, approximately 5.9%, approximately 6%, approximately 6.1%, approximately 6.2%, approximately 6.3%, approximately 6.4%, approximately 6.5%, approximately 6.6%, approximately 6.7%, approximately 6.8%, approximately 6.9%, approximately 7%, approximately 7.1%, approximately 7.2%, approximately 7.3%, approximately 7.4%, approximately 7.5%, approximately 7.6%, approximately 7.7%, approximately 7.8%, approximately 7.9%, approximately 8%, approximately 8.1%, approximately 8.2%, approximately 8.3%, approximately 8.4%, approximately 8.5%, approximately 8.6%, approximately 8.7%, approximately 8.8%, approximately 8.9%, approximately 9%, approximately 9.1%, approximately 9.2%, approximately 9.3%, approximately 9.4%, approximately 9.5%, approximately 9.6%, approximately 9.7%, approximately 9.8%, approximately 9.9%, or approximately 10% Zn. In certain aspects, Zn is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes nickel (Ni) in an amount up to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Ni. In certain aspects, Ni is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes strontium (Sr) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Sr. In certain aspects, Sr is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes calcium (Ca) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Ca. In certain aspects, Ca is not present in the alloy (i.e., 0%). All expressed in wt. %.

In some aspects, the aluminum alloy includes yttrium (Y) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.15% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Y. In certain aspects, Y is not present in the alloy (i.e., 0%). All expressed in wt. %.

The aluminum alloy may also include immiscible elements that do not undergo peritectic or eutectic reactions such as Pb, Bi, In, and Sn.

In some aspects, the aluminum alloy includes manganese (Mn) in an amount from 0% to approximately 2% (e.g., from 0.01% to 2%, from 0.05% to 1.75%, from 0.1% to 1.5%, or from 0.25% to 1%) based on the total weight of the alloy. For example, the alloy can include 0%, approximately 0.05%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.7%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, or approximately 2% Mn. In certain aspects, Mn is not present in the alloy (i.e., 0%). All expressed in wt. %.

Optionally, the aluminum alloy compositions can further include other minor elements, sometimes referred to as impurities, in amounts of approximately 0.05% or below, approximately 0.04% or below, approximately 0.03% or below, approximately 0.02% or below, or approximately 0.01% or below each. These impurities may include, but are not limited to Ga, B, C, Be, or combinations thereof. Accordingly, Ga, B, B, C, or Be may be present in an alloy in amounts of approximately 0.05% or below, approximately 0.04% or below, approximately 0.03% or below, approximately 0.02% or below, or approximately 0.01% or below. In certain aspects, the sum of all impurities does not exceed approximately 0.15% (e.g., approximately 0.1%). All expressed in wt. %. In certain aspects, the remaining percentage of the alloy is aluminum.

The alloy compositions disclosed herein, including the aluminum alloy material of any of foregoing embodiments, have aluminum (Al) as a major component, for example, in an amount of at least 80.0% of the alloy. Optionally, the alloy compositions have at least 85.0% Al, or at least 86.0% Al, or at least 86.5% Al, or at least 87.0% Al, or at least 87.5% Al, or at least 88.0% Al, or at least 88.5% Al, or at least 89.0% Al, or at least 89.5% Al, or at least 90.0% Al, or at least 90.5% Al, or at least 91.0% Al, or at least 91.5% Al, or at least 92.0% Al. All are expressed in wt. %.

In some aspects, a reinforcing material may be added to the alloy to form a metal matrix composite (MMC). MMCs are described in WO 2012/164581, titled “A Process for Producing Reinforced Aluminum-Metal Matrix Composites” and filed on May 30, 2012, the entirety of which is incorporated by reference herein. Such reinforcing materials may include SiC, TiB₂, Al₂O₃, B₄C, TiC, CNT (carbon nanotubes), and others. MMCs are known for their high strength and light weight, and may be used in the automotive industry. In some aspects, the reinforcing material may be present in amounts of up to 20% by weight of the metal matrix composite. Without being bound by theory, it is believed that the functional gradient described herein is applicable to MMCs because having an unrecrystallized region at the center of the MMC product may allow for reducing delamination between the matrix and the reinforcing material.

In some aspects, a reinforcing material may “in-situ” form inside the ingot sump or form during the metal transport system or inside the melting/holding furnace. Such “in-situ” reinforcing materials have better bonding tendency with matrix compared to the “ex-situ” added reinforcing material. Such “in-situ” reinforcing materials may include TiB₂, TiC, NbB₂, Al₂O₃, SiC, ZrB₂, AlB₂, Al₃Ti, Al₇Cr, Al₃Zr, Al₃Nb, Al₃Ta, Al₃V, AlN, Al₃Hf, Al₃HfO, and others.

The aluminum alloy articles disclosed herein can be any suitable aluminum alloy article. As noted above, the articles are formed from an aluminum alloy product having a functional gradient across at least one dimension. In some aspects, the functional gradient is across the thickness of the product. For example, the product may have a central, unrecrystallized region which may exhibit high strength but as outer surfaces of the product may be recrystallized, which may help retain formability. Recrystallization may be quantified based on the aspect ratio of the grains using optical microscopy or by textures using electron backscatter diffraction or X-ray diffraction, as described below.

The aluminum alloy product can have any suitable physical configuration. Optionally, the aluminum alloy product is a rolled aluminum alloy plate, shate or sheet. In some embodiments, the aluminum alloy product is a rolled aluminum alloy shate. In some embodiments, the aluminum alloy product is a rolled aluminum alloy sheet.

The degree of recrystallization or the recrystallization quotient can be determined by any suitable method known in the art. For example, in a micrograph, such as a scanning electron micrograph (SEM) or an optical micrograph (OM), the higher degree of recrystallization or recrystallization quotient can be observed in terms of a grain structure having a higher degree of uniformity. In some other examples, electron backscatter diffraction (EBSD) can also be used to assess the degree of recrystallization. Optionally, the degree of recrystallization is set forth in terms of a “recrystallization quotient,” which, as used herein, refers to the formula: 1−LAGB/(MAGB+HAGB). In some embodiments, a recrystallization quotient may refer to or represent a percentage, amount, or volume of material that is recrystallized as compared to a total amount or volume of material. LAGB refers to the quantity of grain boundaries in a given volume having misorientation between adjacent grains of 2° to 15° (i.e., a quantity of low-angle grain boundaries). MAGB refers to the quantity of grain boundaries in a given volume having misorientation between adjacent grains of greater than 15° but no more than 30° (i.e., the quantity of medium-angle grain boundaries). HAGB refers to the quantity of grain boundaries in a given volume having misorientation between adjacent grains of more than 30° (i.e., the quantity of high-angle grain boundaries). Quantities or values of LAGB, MAGB, and HAGB may be determined by measuring the angle of misorientation between adjacent grains, as recorded by EBSD. The recovery or recrystallization of materials may reduce the stored energy in materials when heavily deformed materials are annealed at high temperature. Recovery competes with recrystallization, as both are driven by the stored energy during annealing. Recovery can be defined as annealing processes occurring in deformed materials that occur without the migration of a high-angle grain boundary. The deformed structure is often a cellular structure with walls having dislocation angles. As recovery proceeds, these cell walls undergo a transition towards a genuine subgrain structure. This occurs through a gradual elimination of extraneous dislocations and the rearrangement of the remaining dislocations into low-angle grain boundaries. However, recrystallization is the formation of a new grain structure in a deformed material by the formation and migration of high angle grain boundaries driven by the stored energy of deformation. Therefore, the LAGB is eliminated during the recrystallization process.

The functional gradient formed as described herein may be across at least one dimension of the aluminum alloy product, such as the thickness and/or the width. Optionally, at least two outer regions of the aluminum alloy product, e.g., at least two parallel surfaces of the product, have a recrystallization quotient that is higher than the recrystallization quotient toward the center of the aluminum alloy product. Optionally, the at least two outer regions have a recrystallization quotient that is at least 0.01 higher (e.g., 0.01-1.0), or at least 0.03 higher, or at least 0.05 higher, or at least 0.07 higher, or at least 0.10 higher, or at least 0.15 higher, or at least 0.20 higher, or at least 0.25 higher, or at least 0.30 higher, or at least 0.35 higher, or at least 0.40 higher, or at least 0.45 higher, or at least 0.50 higher, than the recrystallization quotient of the center of the aluminum alloy product.

The functional gradient may also be understood by reviewing the composition of the aluminum alloy product across the dimension of the functional gradient. For example, the functional gradient may have a greater peritectic forming element content along the centerline of the ingot whereas a greater eutectic forming element content may be present along the outer regions.

Aluminum alloy products as described herein may independently exhibit tensile strengths of from 200 MPa to 700 MPa or even greater than 700 MPa, such as up to 750 MPa, 800 MPa or 850 MPa. For example, a tensile strength may be from 200 MPa to 650 MPa, from 200 MPa to 600 MPa, from 200 MPa to 550 MPa, from 200 MPa to 500 MPa, from 250 MPa to 650 MPa, from 250 MPa to 600 MPa, from 250 MPa to 550 MPa, from 250 MPa to 500 MPa, from 300 MPa to 650 MPa, from 300 MPa to 600 MPa, from 300 MPa to 550 MPa, from 300 MPa to 500 MPa, from 350 MPa to 650 MPa, from 350 MPa to 600 MPa, from 350 MPa to 550 MPa, from 350 MPa to 500 MPa, from 400 MPa to 650 MPa, from 400 MPa to 600 MPa, from 400 MPa to 550 MPa, from 400 MPa to 500 MPa, from 200 MPa to 225 MPa, from 225 MPa to 250 MPa, from 250 MPa to 275 MPa, from 275 MPa to 300 MPa, from 300 MPa to 325 MPa, from 325 MPa to 350 MPa, from 350 MPa to 375 MPa, from 375 MPa to 400 MPa, from 400 MPa to 425 MPa, from 425 MPa to 450 MPa, from 450 MPa to 475 MPa, from 475 MPa to 500 MPa, from 500 MPa to 525 MPa, from 525 MPa to 550 MPa, from 550 MPa to 575 MPa, from 575 MPa to 600 MPa, from 600 MPa to 625 MPa, from 625 MPa to 650 MPa, from 650 MPa to 675 MPa, or from 675 MPa to 700 MPa.

Aluminum alloy products as described herein may independently exhibit yield strengths of from 200 MPa to 600 MPa or even greater than 600 MPa, such as up to 650 MPa, 700 MPa or 750 MPa. For example, a yield strength may be from 200 MPa to 550 MPa, from 200 MPa to 500 MPa, from 250 MPa to 600 MPa, from 250 MPa to 550 MPa, from 250 MPa to 500 MPa, from 300 MPa to 600 MPa, from 300 MPa to 550 MPa, from 300 MPa to 500 MPa, from 350 MPa to 600 MPa, from 350 MPa to 550 MPa, from 350 MPa to 500 MPa, from 400 MPa to 600 MPa, from 400 MPa to 550 MPa, from 400 MPa to 500 MPa, from 200 MPa to 225 MPa, from 225 MPa to 250 MPa, from 250 MPa to 275 MPa, from 275 MPa to 300 MPa, from 300 MPa to 325 MPa, from 325 MPa to 350 MPa, from 350 MPa to 375 MPa, from 375 MPa to 400 MPa, from 400 MPa to 425 MPa, from 425 MPa to 450 MPa, from 450 MPa to 475 MPa, from 475 MPa to 500 MPa, from 500 MPa to 525 MPa, from 525 MPa to 550 MPa, from 550 MPa to 575 MPa, or from 575 MPa to 600 MPa.

Methods of Preparing Aluminum Alloy Products

In certain aspects, the disclosed aluminum alloy products are products of a disclosed method. Without intending to limit the scope of the inventions set forth herein, the properties of the aluminum alloy products set forth herein are partially determined by the formation of certain microstructures during the preparation thereof.

In at least one aspect, the disclosure provides a method of making an aluminum alloy product, the method comprising: providing an aluminum alloy in a molten state as a molten aluminum alloy; casting the molten aluminum alloy to form an aluminum alloy cast product; homogenizing the aluminum alloy cast product to form a homogenized aluminum alloy cast product; and rolling the homogenized aluminum alloy cast product to form a rolled aluminum alloy product. In some aspects, the molten aluminum alloy is cast into an ingot by a direct chill (DC) casting process. In some aspects, the molten aluminum alloy is cast to a casting cavity a continuous (CC) casting process by use of a twin-belt caster, a twin-roll caster, a block caster, or any other continuous caster.

Casting

The methods disclosed herein may comprise a step of adding different alloying elements in the form of master alloy (binary or ternary or quaternary elements) or pure metal to the molten liquid pool. This also may involve stirring the furnace using magnets or manual stirring. Optionally, reinforcement particles may be added. This may involve removing dross.

The methods disclosed herein may comprise a step of using an induction furnace or a gas fire furnace or an electric resistance furnace for preparing the molten liquid.

The methods disclosed herein may comprise a step of casting a molten aluminum alloy to form an aluminum alloy cast product. In some embodiments, the molten alloy may be treated before casting. The treatment can include one or more of furnace fluxing, inline degassing, inline fluxing, and filtering. Aluminum alloy cast products can be formed using any casting process performed according to standards commonly used in the aluminum industry as known to one of ordinary skill in the art, including by direct casting and continuous casting methods as described herein.

In certain aspects, the molten liquid includes dispersed reinforcement particles that may be added just before delivering the molten liquid to the mold using direct casting methods. Additionally or alternatively, the molten liquid includes dispersed reinforcement particles added as a secondary molten liquid deep inside the sump, while the primary molten liquid still flowing. In certain aspects, the secondary molten metal is rich in dispersoid forming elements and directly injected deep inside the sump.

As a few non-limiting examples, the casting process can include a direct chill (DC) casting process or a continuous casting (CC) process. The continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity. In some embodiments, the CC process may include, but is not limited to, the use of twin-belt casters, twin-roll casters, or block casters. In some embodiments, the casting process is performed by a CC process to form a cast product in the form of a billet, a slab, a shate, a strip, and the like. In some aspects, DC casting is used.

A cast product, such as an ingot, billet, slab, shate, strip, etc., can be processed by any means known to those of ordinary skill in the art. Optionally, the processing steps can be used to prepare sheets. Such processing steps can include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and an optional pre-aging step, as known to those of ordinary skill in the art. The processing steps can be suitably applied to any cast product, including, but not limited to, ingots, billets, slabs, strips, plates, shates, etc., using modifications and techniques as known to those of skill in the art. Specific processing steps may be used to prepare aluminum alloy articles with particular recrystallization quotient distributions, as described below.

In some cases, the casting process may impact the recrystallization and reforming that may occur during subsequent processing steps. For example, the distribution of dispersoid-forming elements in a cast product, such as an ingot, may impact the ability of a cast product to undergo recrystallization. By selectively forming primary grains enriched in at least one peritectic forming element and depleted in at least one eutectic element, segregating peritectic (dispersoids) forming elements during the casting process, different regions of the cast products and processed products and articles may be more or less prone to undergo recrystallization. The peritectic forming elements may precipitate out of supersaturated solutions in the form of nano-scale dispersoids, which may be, for example, from 10 nm in diameter to 100 nm in diameter. These dispersoids may have sizes that do not promote recrystallization nucleation in the way that larger particles do. Instead, these particles may inhibit the motion of dislocations and grain boundaries such that recrystallization is inhibited. The volume or mass fraction of these dispersoids may determine or impact the specific recrystallization behavior in a cast product.

In addition to the primary grain size having an impact on the macrosegregation of peritectic elements at the center, an increase in solid solubility of peritectic elements in primary aluminum grains also may determine the amount of macrosegregation in a cast ingot, for example. The increase in solid solubility of peritectic elements is determined by the solidifying path of the primary grains. Once the peritectic elements are in solid solution within the primary grains, thus allowing the primary grains to settle at the ingot center, the peritectic elements may also be precipitated out downstream during the deformation stage irrespective of the primary grain size. As generally dispersoids form during the homogenization process, recrystallization occurs after hot rolling. Hence, the cast primary grain size (or dendritic size) may not be relative to the peritectic (dispersoids) forming elements and recrystallization mechanism. In some instances, there may be a so called “particle free zone” where dispersoids are absent in the primary grains after homogenization. It is believed that this occurs when the peritectic (dispersoids) forming elements distribution across the primary grain varies and the primary grain center is rich in peritectic element and depleted in the direction towards grain (or dendrite) boundary, which may have an on recrystallization.

In large-scale castings, depletion or accumulation of alloying elements can occur. This is known as macrosegregation, which may be caused by the relative movement of solid and liquid phases which are of inherently different compositions. The center of an ingot may be particularly susceptible to macrosegregation, such as during casting. For example, this area of an ingot may exhibit depletion of eutectic forming elements, with the relative depletion proportional to casting speed. This property is further elucidated by Yu and Granger in “Macrosegregation in Aluminum Alloy Ingot Cast by the Semicontinuous Direct Chill (DC) Method, International Conference on Aluminum alloys—Their physical and mechanical properties,” Charlottesville, Virginia. Warley (UK): EMAS; 1986, p. 17-29. As described herein, although this behavior has been previously seen as detrimental, the current inventors instead intentionally formed macrosegregation but used specific methods to form a functional gradient. This functional gradient resulted in an aluminum rolled product having desirable properties and being recyclable. Advantageously, more primary grains are accumulated at the center to provide aluminum alloy products that have a functional gradient across at least one dimension of the product.

Similarly, the peritectic or dispersoid forming elements may also be selectively enriched in the centerline of the ingot, and the enrichment may also be enhanced by increasing the casting speed. Thus, by varying the casting speed, the distributions of dispersoid-forming elements may be optimized at the center of the ingot, which can impact the rate at which recrystallization may occur. For example, by increasing the casting speed in an ingot containing dispersoid-forming elements, the concentration of dispersoid-forming elements at the center of the ingot may be increased as compared to slower casting rates. The enhanced dispersoid content in the corresponding solidified ingot can then be used during subsequent processing steps (e.g., rolling, annealing, etc.) to impact the rate of recrystallization at the center of a processed object. In this way, casting can impact the amount and rate of recrystallization at a center portion relative to surface portions during subsequent rolling and annealing steps, for example. Accordingly, methods disclosed herein may optionally utilize a high-rate casting step, such as about 1.5 inches per minute (IPM) or greater, such as 1.5-10 IPM, 2.5-10 IPM, 3.5-10 IPM, or 4.5-10 IPM.

In order to influence the formation of dispersoids at the desired location, e.g., toward the center of the ingot or toward the exterior surfaces, various parameters in the casting process may be adjusted. For example, in order to enrich the peritectic (dispersoid) elements, the flow of molten metal within the ingot may be controlled. To modify the flow, a high velocity jet melt technique using a tailored nozzle to allow the flow moving towards the short face and rolling face at an angle so the sump profile is steeper, which forces more grains settling to the center. The high velocity jet melt technique may be performed without using magnets. Alternatively, large magnets positioned on each rolling face, and spinning in opposite directions, may be used to create a flow moving from the rolling surface in the direction toward the ingot center. Another alternative to modify the flow may include using a large combo bag with an angled slot to provide a flow moving closer to the end face and allowing more primary grains settling at the bottom of sump centrally. Yet another alternative to modify the flow may include the use of magnetic high velocity liquid jet technique allowing the creation of a deeper sump and thus increased segregation. This may also create more positive segregation of eutectic elements at center of ingot. Additionally or instead of modifying the flow, convective currents may be applied via magnetic means or by physically stirring. These methods may be used to change how the grains settle during casting. In further embodiments, the casting speed may be increased, which may help to increase the depth of the molten pool. Further, increasing the angle of the solidifying interface may lead to increased movement of grains to the bottom of the molten pool in the mold, e.g., toward the ingot center. The process may be adjusted depending on how the functional gradient is desired to flow, e.g., with the dispersoids concentrated in the center of the ingot or toward the surfaces/edges.

Other distinguishing aspects of the casting process that results in the desired ingot may include any of the following aspects. For example, in-situ technology may be used to increase the sump depth and create more macrosegregation. Sump depth may additionally or alternatively be increased using commercial wiper technology. Additionally or alternatively, a secondary liquid jet may be injected wherein the secondary liquid is rich in peritectic element and/or eutectic element (e.g., the possibility of a binary alloy liquid) directly into the sump at a higher depth below the primary liquid jet to greatly increase the segregation fold and may also help to increase the solid solubility of elements in the aluminum primary grains during DC casting, noting that a similar approach can also be applied to CC. Additionally or alternatively, a binary rod may be injected or fed directly inserted into the center of the sump so that upon melting the rod, an increase in those rod elements concentration at center is realized. Additionally or alternatively, a steam of slurry (or liquid including reinforcement particles) may be injected or fed into the center of the sump such that the cast ingot retains a finer particles size without coarsening or agglomerating at the ingot center. Additionally or alternatively, a combination of the aforementioned techniques may be used, such as the combination of the high velocity liquid jet technique used along with commercial wipers and/or by varying casting speed to provide enhanced macrosegregation.

Homogenization

The homogenization step can include heating an aluminum alloy cast product prepared from an alloy composition described herein to attain a peak metal temperature (PMT) of at least 400° C. (e.g., at least 400° C., at least 410° C., at least 420° C., at least 430° C., at least 440° C., at least 450° C., at least 460° C., at least 470° C., at least 480° C., at least 490° C., at least 500° C., at least 510° C., at least 520° C., or at least 530° C.). For example, the aluminum alloy product can be heated to a temperature of from 400° C. to 580° C., from 420° C. to 575° C., from 440° C. to 570° C., from 460° C. to 565° C., from 485° C. to 560° C., from 500° C. to 560° C., or from 520° C. to 580° C. Optionally, the heating rate to the PMT is 100° C./hour or less, 75° C./hour or less, 50° C./hour or less, 40° C./hour or less, 30° C./hour or less, 25° C./hour or less, 20° C./hour or less, or 15° C./hour or less. Optionally, the heating rate to the PMT is from 10° C./min to 100° C./min (e.g., 10° C./min to 90° C./min, 10° C./min to 70° C./min, 10° C./min to 60° C./min, from 20° C./min to 90° C./min, from 30° C./min to 80° C./min, from 40° C./min to 70° C./min, or from 50° C./min to 60° C./min).

In some instances, the aluminum alloy cast product is then allowed to soak (i.e., held at a particular temperature, such as a PMT) for a period of time. In some embodiments, the aluminum alloy cast product is allowed to soak for up to 24 hours (e.g., from 30 minutes to 6 hours, inclusively). For example, in some embodiments, the aluminum alloy product is soaked at a temperature of at least 400° C. for 30 minutes, for 1 hour, for 2 hours, for 3 hours, for 4 hours, for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours, for 10 hours, for 11 hours, for 12 hours, for 13 hours, for 14 hours, for 15 hours, for 16 hours, for 17 hours, for 18 hours, for 19 hours, for 20 hours, for 21 hours, for 22 hours, for 23 hours, for 24 hours, or for any time period in between.

In some embodiments, the homogenization described herein can be carried out in a two-stage homogenization process. In some embodiments, the homogenization process can include the above-described heating and soaking steps, which can be referred to as the first stage, and can further include a second stage. In the second stage of the homogenization process, the temperature of the aluminum alloy cast product is increased to a temperature higher than the temperature used for the first stage of the homogenization process. The aluminum alloy cast product temperature can be increased, for example, to a temperature at least 5° C. higher than the aluminum alloy cast product temperature during the first stage of the homogenization process. For example, the aluminum alloy cast product temperature can be increased to a temperature of at least 405° C. (e.g., at least 410° C., at least 415° C., or at least 420° C.). The heating rate to the second stage homogenization temperature can be 5° C./hour or less, 3° C./hour or less, or 2.5° C./hour or less. The aluminum alloy cast product is then allowed to soak for a period of time during the second stage. In some embodiments, the aluminum alloy cast product is allowed to soak for up to 10 hours (e.g., from 30 minutes to 10 hours, inclusively). For example, the aluminum alloy cast product can be soaked at the temperature of at least 405° C. for 30 minutes, for 1 hour, for 2 hours, for 3 hours, for 4 hours, for 5 hours, for 6 hours, for 7 hours, for 8 hours, for 9 hours, or for 10 hours. In some embodiments, following homogenization, the aluminum alloy cast product is allowed to cool to room temperature in the air.

The homogenization step may allow for the precipitation of the peritectic or dispersoid phases formed during casting. As described herein, the ingot may have a greater amount of peritectic forming elements at the ingot center, though this may also be reversed to have a greater amount of dispersoids at the surface, if desired.

A temperature gradient inside the homogenization furnace can be used to produce variation in microstructure across the ingot cross-section. For, example a temperature difference between the surface and center of ingot provides for a variation in dispersoid formation.

After homogenization, a quenching water can be applied on the surface of ingot for few second so that the outer surface cools faster and maintaining the inner surface at a higher temperature, which may also promote a gradient in microstructure across the cross-section. A gradient in microstructure may include at least one of a gradient in chemical composition, primary grains distribution, insoluble intermetallic particles (type, size, shape, distribution), texture, or the distribution of recrystallized grains, strengthening precipitates, and/or reinforcement particles.

Hot Rolling

Following the homogenization step, one or more hot rolling passes may be performed. The hot rolling pass is the step when the gradient microstructure is considered formed, as the dispersoid phases serve to inhibit recrystallization. As described above, the dispersoid phases may be present in a greater amount at the ingot center, or at the ingot surfaces, depending on the desired end use and desired properties.

In certain cases, the aluminum alloy products are hot rolled at a temperature ranging from 250° C. to 550° C. (e.g., from 300° C. to 500° C., or from 350° C. to 450° C., or from 300° C. to 520° C.). In some aspects, to manipulate the grain growth processes following recrystallization, the aluminum alloy products are selectively heated during rolling, e.g., by using different temperature profiles to provide gradient heating. The gradient heating may use magnetic, microwave, or inductive heating methods. For example, gradient heating may include heating a sheet or heavy shear gauge plate such that an outer portion has a temperature above the recrystallization temperature and an inner portion has a temperature below the recrystallization temperature. Alternatively or additionally, spray water may be immediately applied after heating so that the outer portion falls immediately to a temperature below the recrystallization temperature while the inner portion maintains a temperature above the recrystallization temperature.

In certain embodiments, the aluminum alloy product is hot rolled to a 4 mm to 15 mm thick gauge (e.g., from 5 mm to 12 mm thick gauge), which is referred to as a shate. For example, the aluminum alloy product can be hot rolled to a 15 mm thick gauge, a 14 mm thick gauge, a 13 mm thick gauge, a 12 mm thick gauge, a 11 mm thick gauge, a 10 mm thick gauge, a 9 mm thick gauge, a 8 mm thick gauge, a 7 mm thick gauge, a 6 mm thick gauge, or a 5 mm thick gauge, or anywhere in between.

In certain other embodiments, the aluminum alloy product can be hot rolled to a gauge greater than 15 mm thick (i.e., a plate). For example, the aluminum alloy product can be hot rolled to a 25 mm thick gauge, a 24 mm thick gauge, a 23 mm thick gauge, a 22 mm thick gauge, a 21 mm thick gauge, a 20 mm thick gauge, a 19 mm thick gauge, a 18 mm thick gauge, a 17 mm thick gauge, or a 16 mm thick gauge, or any suitable gauge in between or above 25 mm thick.

In certain other embodiments, the aluminum alloys product can be cross-rolled in side way.

In other cases, the aluminum alloy product can be hot rolled to a gauge less than 4 mm (i.e., a sheet). For example, the aluminum alloy product can be hot rolled to a 3.5 mm thick gauge, a 3 mm thick gauge, a 2 mm thick gauge, or a 1 mm thick gauge, or anywhere in between.

Cold Rolling and Annealing and Further Rolling

Following the hot rolling, one or more cold rolling passes may be performed. In certain embodiments, the rolled product from the hot rolling step (e.g., the plate, shate, or sheet) can be cold rolled to a thin gauge shate or sheet. In some embodiments, this thin-gauge shate or sheet is cold rolled to have a thickness (i.e., a first thickness) ranging from 0.9 mm to 12.0 mm, or from 2.0 mm to 8.0 mm, or from 3.0 mm to 6.0 mm, or from 4.0 mm to 5.0 mm. In some embodiments, this thin-gauge shate or sheet is cold rolled to have a thickness 12.0 mm, 11.9 mm, 11.8 mm, 11.7 mm, 11.6 mm, 11.5 mm, 11.4 mm, 11.3 mm, 11.2 mm, 11.1 mm, 11.0 mm, 10.9 mm, 10.8 mm, 10.7 mm, 10.6 mm, 10.5 mm, 10.4 mm, 10.3 mm, 10.2 mm, 10.1 mm, 10.0 mm, 9.9 mm, 9.8 mm, 9.7 mm, 9.6 mm, 9.5 mm, 9.4 mm, 9.3 mm, 9.2 mm, 9.1 mm, 9.0 mm, 8.9 mm, 8.8 mm, 8.7 mm, 8.6 mm, 8.5 mm, 8.4 mm, 8.3 mm, 8.2 mm, 8.1 mm, 8.0 mm, 7.9 mm, 7.8 mm, 7.7 mm, 7.6 mm, 7.5 mm, 7.4 mm, 7.3 mm, 7.2 mm, 7.1 mm, 7.0 mm, 6.9 mm, 6.8 mm, 6.7 mm, 6.6 mm, 6.5 mm, 6.4 mm, 6.3 mm, 6.2 mm, 6.1 mm, 6.0 mm, 5.9 mm, 5.8 mm, 5.7 mm, 5.6 mm, 5.5 mm, 5.4 mm, 5.3 mm, 5.2 mm, 5.1 mm, 5.0 mm, 4.9 mm, 4.8 mm, 4.7 mm, 4.6 mm, 4.5 mm, 4.4 mm, 4.3 mm, 4.2 mm, 4.1 mm, 4.0 mm, 3.9 mm, 3.8 mm, 3.7 mm, 3.6 mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm, 3.1 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm or 0.9 mm or anywhere in between.

In some embodiments, the one or more cold rolling passes reduce the thickness of rolled aluminum product by at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at least 55%, or at least 60%, or at least 65%, or at least 70%. In some embodiments, the one or more cold rolling passes reduce the cast product to a thickness (i.e., a first thickness) of no more than 10 mm, or no more than 9 mm, or no more than 8 mm, or no more than 7 mm, or no more than 6 mm, or no more than 5 mm.

Following one or more cold rolling passes, annealing may be performed. This can also be referred to as an intermediate annealing or inter-annealing, as it is performed in the middle of the rolling process, as, in some embodiments, one or more additional rolling passes are carried out after the annealing.

The annealing step can include heating the rolled aluminum product from room temperature to a temperature from 380° C. to 500° C. (e.g., from 385° C. to 495° C., from 390° C. to 490° C., from 395° C. to 485° C., from 400° C. to 480° C., from 405° C. to 475° C., from 410° C. to 470° C., from 415° C. to 465° C., from 420° C. to 460° C., from 425° C. to 455° C., from 430° C. to 460° C., from 380° C. to 450° C., from 405° C. to 475° C., or from 430° C. to 500° C.).

This intermediate annealing step can, for example, lead to certain beneficial texture features in the resulting product. In particular, the intermediate annealing assists in the formation of the recrystallized microstructure on the surface of the product and the recovered and/or unrecrystallized structure in the middle of the product. In some examples, the texture on surface of the product will be dominated by recrystallization components, including cube, cube ND, and cube RD, rather than deformation type components, such as Bs, S, and Cu. Therefore, the bending performance of the product is improved without reducing the strength.

The plate, shate, or sheet can soak at the intermediate annealing temperature for a period of time. In one non-limiting example, the plate, shate, or sheet is allowed to soak for up to approximately 2 hours (e.g., from about 15 to about 120 minutes, inclusively). For example, the plate, shate, or sheet can be soaked at the temperature of from about 400° C. to about 500° C. for 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75 minutes, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110 minutes, 115 minutes, or 120 minutes, or anywhere in between.

In some embodiments, the intermediate annealing of the rolled aluminum alloy product is carried out at a temperature of no more than 45° C., or no more than 40° C., or no more than 35° C., or no more than 30° C., or no more than 25° C., or no more than 20° C., or no more than 15° C., or no more than 10° C., above the minimum recrystallization temperature of the aluminum alloy. In some embodiments, the intermediate annealing of the rolled aluminum alloy product is carried out at a temperature above the minimum recrystallization temperature of the aluminum alloy for no more than 3.0 hours, or no more than 2.5 hours, or no more than 2.0 hours, or no more than 1.5 hours, or no more than 1.0 hours.

Optionally, the intermediate annealing may comprise multiple annealing sub-steps. For example, in some embodiments, the annealing is carried out at a first temperature above the minimum recrystallization temperature for a first period of time and at a second temperature above the minimum recrystallization temperature for a second period of time. For example, the first temperature above the minimum recrystallization temperature may be greater than the second temperature above the minimum recrystallization temperature. Annealing may, for example, subject the surface portions to higher temperature annealing conditions at earlier times than the intermediate portion. By using a two (or more) step intermediate annealing process in which the temperature at the second step is lower than that at the first step, the surface portions of the rolled aluminum alloy product may be subjected to recrystallization conditions for longer periods of time than the intermediate portion. This may also occur in a single step intermediate annealing process in which a single annealing temperature is used, but the effect may be more pronounced in a multiple step annealing process.

Optionally, following the intermediate annealing, further rolling is performed, such as cold rolling. In some embodiments, one or more additional cold rolling passes are performed. This additional rolling brings the aluminum alloy product to a final thickness (i.e., a second thickness). In some embodiments, the final thickness ranges from 0.1 mm to 4.0 mm. In some embodiments, the final thickness is 4.0 mm, 3.9 mm, 3.8 mm, 3.7 mm, 3.6 mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm, 3.1 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm, or 0.1 mm. In some further such embodiments, the final thickness is no more than 4.0 mm, or no more than 3.5 mm, or no more than 3.0 mm, or no more than 2.5 mm, or no more than 2.0 mm, or no more than 1.5 mm, or no more than 1.0 mm, or no more than 0.5 mm, or no more than 0.3 mm, or no more than 0.1 mm.

Finishing Steps

Optionally, following the intermediate annealing and/or the additional rolling, additional finishing steps can be carried out, including, but not limited to, one or more of solutionizing, quenching, ageing, and coiling.

In some embodiments, a solution heat treatment step can be carried out. The solution heat treatment step can include heating the aluminum alloy product from room temperature to a temperature of from 430° C. to 580° C. For example, the solution heat treatment step can include heating the aluminum alloy product from room temperature to a temperature of from 440° C. to 580° C., from 460° C. to 500° C., or from 480° C. to 490° C. In some examples, the heating rate for the solution heat treatment step can be from 250° C./hour to 350° C./hour (e.g., 250° C./hour, 255° C./hour, 260° C./hour, 265° C./hour, 270° C./hour, 275° C./hour, 280° C./hour, 285° C./hour, 290° C./hour, 295° C./hour, 300° C./hour, 305° C./hour, 310° C./hour, 315° C./hour, 320° C./hour, 325° C./hour, 330° C./hour, 335° C./hour, 340° C./hour, 345° C./hour, or 350° C./hour).

In some embodiments, the aluminum alloy product can then be cooled to a temperature of about 25° C. at a quench speed that can vary between about 50° C./s to 400° C./s in a quenching step that is based on the selected gauge. For example, the quench rate can be from about 50° C./s to about 375° C./s, from about 60° C./s to about 375° C./s, from about 70° C./s to about 350° C./s, from about 80° C./s to about 325° C./s, from about 90° C./s to about 300° C./s, from about 100° C./s to about 275° C./s, from about 125° C./s to about 250° C./s, from about 150° C./s to about 225° C./s, or from about 175° C./s to about 200° C./s.

In the quenching step, the aluminum alloy product is rapidly quenched with a liquid (e.g., water) and/or gas or another selected quench medium. In certain aspects, the aluminum alloy product can be rapidly quenched with water. In certain embodiments, the aluminum alloy product is quenched with air.

In some embodiments, the aluminum alloy product can be artificially aged for a period of time to result in the T6 or T7 temper. In certain embodiments, the aluminum alloy product can be artificially aged (AA) at about 100° C. to 225° C. (e.g., 100° C., 105° C., 110° C., 115° C., 120° C., 125° C., 130° C., 135° C., 140° C., 145° C., 150° C., 155° C., 160° C., 165° C., 170° C., 175° C., 180° C., 185° C., 190° C., 195° C., 200° C., 205° C., 210° C., 215° C., 220° C., or 225° C.) for a period of time. Optionally, the aluminum alloy product can be cold worked and artificially aged for a period from about 15 minutes to about 48 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, 37 hours, 38 hours, 39 hours, 40 hours, 41 hours, 42 hours, 43 hours, 44 hours, 45 hours, 46 hours, 47 hours, or 48 hours, or anywhere in between).

In some embodiments, an annealing step during or after production can also be applied to produce the aluminum alloy product in a coil form for improved productivity or formability. For example, an alloy in coil form can be supplied in the O temper, using a hot or cold rolling step and an annealing step following the hot or cold rolling step. Forming may occur in O temper, which is followed by solution heat treatment, quenching and artificial aging/paint baking.

In certain aspects, to produce an aluminum alloy product in coil form and with high formability compared to F temper, an annealing step can be applied to the coil. Without intending to limit the invention, the purpose for the annealing and the annealing parameters may include (1) releasing the work-hardening in the material to gain formability; (2) recrystallizing or recovering the material without causing significant grain growth; (3) engineering or converting texture to be appropriate for forming and for reducing anisotropy during formability; and (4) avoiding the coarsening of pre-existing precipitation particles.

In one or more aspects, the disclosure provides aluminum alloy products formed by the processes set forth above, or any embodiments thereof.

Articles of Manufacture

The disclosure provides an article of manufacture, which is comprised of an aluminum alloy product disclosed herein. In some embodiments, the article of manufacture is comprised of a rolled aluminum alloy product. Examples of such articles of manufacture include, but are not limited to, an automobile, a truck, a trailer, a train, a railroad car, an airplane, an armored vehicle, a ship, a boat, a body panel or part for any of the foregoing, a bridge, a pipeline, a pipe, a tubing, a boat, a ship, a storage container, a storage tank, a an article of furniture, a window, a door, a railing, a functional or decorative architectural piece, a pipe railing, an electrical component, a conduit, a beverage container, a food container, or a foil.

In some other embodiments, the aluminum alloy articles disclosed herein can be used in automotive and/or transportation applications, including motor vehicle, aircraft, and railway applications, or any other desired application. In some examples, the aluminum alloy products disclosed herein can be used to prepare motor vehicle body part products, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloys and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

In some other embodiments, the aluminum alloy articles disclosed herein can be used in electronics applications. For example, the aluminum alloy products disclosed herein can also be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the alloys can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones) and tablet bottom chassis.

In some other embodiments, the aluminum alloy products disclosed herein can be used in industrial applications. For example, the aluminum alloy products disclosed herein can be used to prepare products for the general distribution market.

In some other embodiments, the aluminum alloy articles disclosed herein can be used as aerospace body parts. For example, the aluminum alloy articles disclosed herein can be used to prepare structural aerospace body parts, such as a wing, a fuselage, an aileron, a rudder, an elevator, a cowling, or a support. In some other embodiments, the aluminum alloy articles disclosed herein can be used to prepare non-structural aerospace body parts, such as a seat track, a seat frame, a panel, or a hinge.

The following examples serve to further illustrate certain embodiments of the present disclosure without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those of ordinary skill in the art without departing from the spirit of the disclosure.

Illustrative Aspects

As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or non-enumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4”). Aspect 1 is a method of preparing a functionally gradient aluminum alloy product, comprising: casting an ingot in a mold or a molten liquid to a casting cavity to form a cast product, the cast product including an aluminum alloy, and the cast product comprising at least one peritectic forming element and at least one eutectic forming element, wherein the casting comprises: a) forming primary grains enriched in the at least one peritectic forming element and depleted in the at least one eutectic element; and b) controlling movement and accumulation of the primary grains; homogenizing the cast product, wherein during homogenization, the primary grains are precipitated; and rolling the homogenized cast product to form the functionally gradient aluminum alloy product.

Aspect 2 is the method of any previous or subsequent aspect, wherein the aluminum alloy is a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

Aspect 3 is the method of any previous or subsequent aspect, wherein the at least one peritectic forming element is present in an amount of 0.2% by weight or less.

Aspect 4 is the method of any of any previous or subsequent aspect, wherein the at least one eutectic forming element is present in an amount of greater than 0.2% by weight.

Aspect 5 is the method of any of any previous or subsequent aspect, wherein the casting an ingot in a mold comprises a direct chill casting process.

Aspect 6 is the method of any of any previous or subsequent aspect, wherein the casting a molten liquid to a casting cavity comprises a continuous casting process.

Aspect 7 is the method of any previous or subsequent aspect, wherein the continuous casting process includes casting with at least one of a twin-belt caster, a twin-roll caster, a block caster, or any other continuous caster.

Aspect 8 is the method of any of any previous or subsequent aspect, wherein the rolling comprises hot rolling.

Aspect 9 is the method of any of any previous or subsequent aspect, wherein the precipitated primary grains inhibit recrystallization during the rolling.

Aspect 10 is the method of any of any previous or subsequent aspect, wherein the aluminum alloy product is functionally gradient across a thickness of the product.

Aspect 11 is the method of any of any previous or subsequent aspect, wherein the aluminum alloy product is functionally gradient across a width of the product.

Aspect 12 is the method of any of any previous or subsequent aspect, wherein the primary grains have a largest dimension from 25 to 250 microns.

Aspect 13 is the method of any of any previous or subsequent aspect, wherein the aluminum alloy comprises the at least one peritectic forming element and the at least one eutectic forming element.

Aspect 14 is the method of any of any previous or subsequent aspect, wherein the at least one peritectic forming element, the at least one eutectic forming element, or combinations thereof are added to the ingot or liquid metal during casting.

Aspect 15 is the method of any of any previous or subsequent aspect, wherein forming primary grains further includes forming at least one of solute elements, intermetallic particles, solute rich grains, reinforcement particles, or combinations thereof.

Aspect 16 is an aluminum alloy product comprising a functional gradient across at least one dimension, wherein the functional gradient comprises an unrecrystallized center and a recrystallized surface, and/or a reinforcement particle proportion variation from center to surface.

Aspect 17 is the aluminum alloy product of any previous or subsequent aspect, wherein the product comprises at least one peritectic forming element in the unrecrystallized center.

Aspect 18 is the aluminum alloy product of any previous or subsequent aspect, wherein the at least one peritectic forming element comprises at least one of Ti, Zr, V, Hf, Nb, Ta, Cr, or combinations thereof.

Aspect 19 is the aluminum alloy product of any previous or subsequent aspect, wherein the at least one peritectic element is present in an amount of 0.2% by weight or less.

Aspect 20 is the aluminum alloy product of any of any previous or subsequent aspect, wherein the product comprises at least one eutectic forming element in the recrystallized surface.

Aspect 21 is the aluminum alloy product of any previous or subsequent aspect, wherein the eutectic forming element comprises at least one of Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce, and Y and combinations thereof.

Aspect 22 is the aluminum alloy product of any previous or subsequent aspect, wherein the eutectic forming element is present in an amount of greater than 0.2% by weight.

Aspect 23 is the aluminum alloy product of any previous or subsequent aspect, wherein the product may comprises at least one reinforcement particle.

Aspect 24 is the aluminum alloy product of any previous or subsequent aspect, wherein the reinforcement particle comprises at least one of TiB₂, TiC, NbB₂, Al₂O₃, SiC, ZrB₂, AlB₂, Al₃Ti, Al₇Cr, Al₃Zr, Al₃Nb, Al₃Ta, Al₃V, AlN, Al₃Ni, Al₃Hf, Al₃HfO, and combinations thereof.

Aspect 25 is the aluminum alloy product of any previous or subsequent aspect, wherein the reinforcement particle is either added to molten metal or formed in-situ during casting.

Aspect 26 is the aluminum alloy product of any of any previous or subsequent aspect, wherein the reinforcement particle is present in an amount greater than 0.1% by weight.

Aspect 27 is an aluminum alloy article comprising the aluminum alloy product of any of any previous aspect.

All patents, patent applications, publications, and abstracts cited above are incorporated herein by reference in their entirety. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those of ordinary skill in the art without departing from the spirit and scope of the invention as defined in the following claims. 

1. A method of preparing a functionally gradient aluminum alloy product, comprising: casting an ingot in a mold or a molten liquid to a casting cavity to form a cast product, the cast product including an aluminum alloy, and the cast product comprising at least one peritectic forming element and at least one eutectic forming element, wherein the casting comprises: a) forming primary grains enriched in the at least one peritectic forming element and depleted in the at least one eutectic element; and b) controlling movement and accumulation of the primary grains; homogenizing the cast product, wherein during homogenization, the primary grains are precipitated; and rolling the homogenized cast product to form the functionally gradient aluminum alloy product.
 2. The method of claim 1, wherein the aluminum alloy is a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.
 3. The method of claim 1, wherein the at least one peritectic forming element is present in an amount of 0.2% by weight or less.
 4. The method of claim 1, wherein the at least one eutectic forming element is present in an amount of greater than 0.2% by weight.
 5. The method of claim 1, wherein the casting an ingot in a mold comprises a direct chill casting process.
 6. The method of claim 1, wherein the casting a molten liquid to a casting cavity comprises a continuous casting process.
 7. The method of claim 6, wherein the continuous casting process includes casting with at least one of a twin-belt caster, a twin-roll caster, a block caster, or any other continuous caster.
 8. The method of claim 1, wherein the rolling comprises hot rolling.
 9. The method of claim 1, wherein the precipitated primary grains inhibit recrystallization during the rolling.
 10. The method of claim 1, wherein the aluminum alloy product is functionally gradient across a thickness of the product.
 11. The method of claim 1, wherein the aluminum alloy product is functionally gradient across a width of the product.
 12. The method of claim 1, wherein the primary grains have a largest dimension from 25 to 250 microns.
 13. The method of claim 1, wherein the aluminum alloy comprises the at least one peritectic forming element and the at least one eutectic forming element.
 14. The method of claim 1, wherein the at least one peritectic forming element, the at least one eutectic forming element, or combinations thereof are added to the ingot or liquid metal during casting.
 15. The method of claim 1, wherein forming primary grains further includes forming at least one of solute elements, intermetallic particles, solute rich grains, reinforcement particles, or combinations thereof.
 16. An aluminum alloy product comprising a functional gradient across at least one dimension, wherein the functional gradient comprises an unrecrystallized center and a recrystallized surface, and/or a reinforcement particle proportion variation from center to surface.
 17. The aluminum alloy product of claim 16, wherein the product comprises at least one peritectic forming element in the unrecrystallized center.
 18. The aluminum alloy product of claim 17, wherein the at least one peritectic forming element comprises at least one of Ti, Zr, V, Hf, Nb, Ta, Cr, or combinations thereof.
 19. The aluminum alloy product of claim 17, wherein the at least one peritectic element is present in an amount of 0.2% by weight or less.
 20. The aluminum alloy product of claim 16, wherein the product comprises at least one eutectic forming element in the recrystallized surface. 21-27. (canceled) 